Multilayered coated cutting tool

Description

BACKGROUND OF THE INVENTION

The present invention relates to a tool for machining by chip removal comprising a body of a hard alloy of cemented carbide, cermet, ceramics, cubic boron nitride based material or high speed steel and a hard and wear resistant metal nitride coating comprising alternating cubic structured (Ti,Al)N layers and cubic structured MeN layers, where Me is one or more of the metal elements Ti, Zr, Hf, V, Nb, Ta, Mo and Al. The coating is grown by physical vapour deposition (PVD) and preferably by cathodic arc evaporation. This invention is particularly useful in metal cutting applications generating high temperatures, e.g., machining of super alloys and stainless steel.

Since the early 1980's, TiN-layers have been widely used for surface protective applications. In order to improve the oxidation resistance of these coatings, work began in the mid-1980's with adding aluminium to TiN [see e.g. H. A. Jehn, et al, J. Vac. Sci. Technol. A 4, 2701 (1986) and 0. Knotek et. al, J. Vac. Sci. Technol. A 4, 2695 (1986)]. The compound thus formed, cubic-phase (Ti,Al)N, was found to have superior oxidation resistance and enabled greater cutting speeds during machining, prolonged tool life, machining of harder materials, and improved manufacturing economy. Improved coating performance in metal cutting applications has been obtained by precipitation hardening of (Ti,Al)N [see e.g. A. Hörling et al, Surf. Coat. Tech. 191 (2005)] and also disclosed in U.S. Pat. No. 7,083,868 and U.S. Pat. No. 7,056,602.

Coating optimization has also been obtained by applying different concepts of multilayer as; alternating Ti and Al containing layers (U.S. Pat. No. 6,309,738), oxygen and non-oxygen containing layers (U.S. Pat. No. 6,254,984), one of the layers stacked in the multilayer consists itself of a multilayer (U.S. Pat. No. 6,077,596), alternating nitrogen content (U.S. Pat. No. 5,330,853) or using one metastable compound (U.S. Pat. No. 5,503,912) or as aperiodic multilayer (U.S. Pat. No. 6,103,357).

JP 6136514 discloses a wear resistant multilayered hard coating structure comprising alternating layers of Ti(C, N) and (Al, Ti)(C, N) on the surface of the tool. The coating is deposited by PVD at a relatively low temperature.

The trends towards dry-work processes for environmental protection, i.e., metal cutting operation without using cutting fluids (lubricants) and accelerated machining speed with improved process put even higher demands on the characteristics of the tool materials due to an increased tool cutting-edge temperature. In particular, coating stability at high temperatures, e.g., oxidation- and wear-resistance have become even more crucial.

It is an object of the present invention to provide a coated cutting tool yielding improved performance in metal cutting applications at elevated temperatures.

Surprisingly, we have found that by combining two different cubic structured materials in a multilayered coating leads to improved high temperature metal cutting properties. The coating hardens as a nanocomposite, adapting its strength during spinodal decomposition of (Ti,Al)N in cubic TiN and cubic AlN domains where the additional MeN layers provide means for locking a predominantly overall cubic coating structure (as measured by X-ray diffraction) thus suppressing the detrimental hexagonal AlN phase formation otherwise occurring.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a; Schematic coating structure showing (1) body, (2) multilayer coating, (3) MeN layer, (4) (Ti, Al)N layer and (5) the repeat period λ.

FIG. 1b; Schematic coating structure showing (1) body, (2) inner single- and/or multilayer coating according to prior art, (3) multilayer coating according to the invention and (4) outer single- and/or multilayer coating according to prior art.

FIG. 2a; Schematic view (side view) of the deposition chamber showing (1) vacuum chamber, (2a) cathode material A, (2b) cathode material B, (3) fixture, (4) power supply for biasing, (5a) cathodic arc power supply (5b) cathodic arc power supply, (6) inlet for process gas and (7) outlet for vacuum pump.

FIG. 2b; Schematic view (top view) of the deposition chamber showing (1) vacuum chamber, (2) four positions for different cathode materials and (3) fixture.

FIG. 3; (A) Cross sectional STEM micrograph of a coating with TiN (bright contrast) and (Ti,Al)N (dark contrast) and (B) schematic representation of the grain structure of a typical multilayer coating according to this invention.

FIG. 4; X-ray diffraction patterns obtained from (A) a pure (Ti,Al)N layer and (B) a multilayer TiN/(Ti,Al)N coating according to the invention. The diffraction peaks are indexed as (1) TiN, (2) (Ti,Al)N and (3) cemented carbide.

FIG. 5; Schematic of the set-up used for residual stress, σ, analysis by XRD

FIG. 6; STEM micrographs of a TiN/(Ti,Al)N multilayer coating of TiN (2 nm) and (Ti,Al)N (7.9 nm) showing (A) the (Ti,Al)N layer, (B) electron diffraction pattern over the region in (A), (C) Ti EDS map (bright contrast) and (D) Al EDS map (bright contrast).

DETAILED DESCRIPTION OF THE INVENTION

According to the present invention, there is provided a cutting tool for machining by chip removal comprising a body of a hard alloy of cemented carbide, cermet, ceramics, cubic boron nitride based material or high speed steel on which a hard and wear resistant coating is applied comprising a polycrystalline laminar, multilayered structure of metal nitride compounds, in a repetitive form (see FIG. 1a). MeN(3)/(Ti_1-xAl_x)N(4)/MeN(3)/(Ti_1-xAl_x)N(4)/MeN(3)/(Ti_1-xAl_x)N(4)/MeN(3)/ . . . of cubic structured (Ti_1-xAl_x)N layers 0.3<x<0.95, preferably 0.45<x<0.75 and cubic structured MeN layers where Me is one or more of the metal elements Ti, Zr, Hf, V, Nb, Ta, Mo and Al, preferably Ti, V, Nb, Ta and Al.

Said laminar structure has a total thickness of 0.5 to 20 μm, preferably 1 to 10 μm and most preferably 2 to 5 μm. The repeat period λ, (5) in FIG. 1a, i.e., the total thickness of the bi-layer d_MeN+d_(Ti,Al)N, is essentially constant throughout the entire multi layer structure (that is, it varies by no more than 20%). The repeat period is 5 nm≦λ≦20 nm, preferably 5 nm≦λ≦10 nm with 1/10<(d_MeN/d_(Ti,Al)N)<1/3 and where the thickness d_MeN is larger than d_MeN≧1 nm.

In a first embodiment Me is Ti.

In a second embodiment Me is Zr.

In a third embodiment Me is V.

In a forth embodiment Me is Nb.

In a fifth embodiment Me is Ta.

In a sixth embodiment Me is Al.

In a seventh embodiment Me is two or more of the metal elements Ti, V, Nb or Al.

In an eighth embodiment Me is two or more of the metal elements V, Nb or Al.

In a ninth embodiment Me is two or more of the metal elements Ti, Zr, V or Nb.

In a tenth embodiment Me is two or more of the metal elements Zr, V or Nb.

Said body (1) in FIG. 1b may be coated with an inner (3) single- and/or multilayer coating of TiN, TiC, Ti(C,N) or (Ti,Al)N, preferably (Ti,Al)N and/or an outer (4) single- and/or multilayer coating of TiN, TiC, Ti(C,N) or (Ti,Al)N, preferably (Ti,Al)N, to a total coating thickness 1 to 20 μm, preferably 1 to 10 μm and most preferably 2 to 7 μm according to prior art.

The MeN layer has a compressive stress level between −12.0<σ(MeN)<−3.0 GPa, preferably between −12.0<σ(MeN)<−8.0 GPa whereas the (Ti_1-xAl_x)N layer has a stress level varying between −6.0<σ((Ti_1-xAl_x)N)<−0.5 GPa, preferably between −6.0<σ((Ti_1-xAl_x)N)<−3.0 GPa.

The average composition of the MeN/(Ti_1-xAl_x)N multilayer coating is 46 at %<Zr+Hf+V+Nb+Ta+Mo+Ti+Al<54 at %, preferably 48 at %<Zr+Hf+V+Nb+Ta+Mo+Ti+Al<52 at % and balanced N.

The coating process of the present invention is based on cathodic arc evaporation of pure and/or alloyed cathodes under the following conditions; (Ti_1-xAl_x)N layers are grown using Ti/Al-cathodes with a composition between (70 at % Ti+30 at % Al) and (5 at % Ti+95 at % Al) and preferably between (40 at % Ti+60 at % Al) and (30 at % Ti+70 at % Al). The MeN layers are grown using pure or alloyed cathodes where Me is one or more of the metal elements Ti, Zr, Hf, V, Nb, Ta, Mo and Al, preferably one or more of Ti, V, Nb, Ta or Al. The evaporation current is between 50 A and 200 A depending on the cathode size and preferably between 50 A and 100 A using cathodes of 63 mm in diameter. The layers are grown in an Ar+N₂ atmosphere, preferably in a pure N₂ atmosphere, at a total pressure of 0.5 Pa to 9.0 Pa, preferably 1.5 Pa to 5.0 Pa. The bias is −10 V to −300 V, preferably −20 V to −100V. The deposition temperature is between 350° C. and 700° C., preferably between 400° C. and 650° C.

The invention also relates to the use of cutting tool inserts according to the above for machining of stainless steel and super alloys at cutting speeds of 50-400 m/min, preferably 75-300 m/min, with an average feed, per tooth in the case of milling, of 0.08-0.5 mm, preferably 0.1-0.4 mm depending on cutting speed and insert geometry.

Example 1

Cemented carbide inserts with composition 94 wt % WC−6 wt % Co (WC grain size of 0.8 μm) were used.

Before deposition, the inserts were cleaned in ultrasonic baths of an alkali solution and alcohol. The system was evacuated to a pressure of less than 2.0×10⁻³ Pa, after which the inserts were sputter cleaned with Ar ions. TiN/(Ti_1-xAl_x)N layers were grown using cathodic arc evaporation. The cathode materials for (Ti_1-xAl_x)N was Ti/Al (33 at % Ti+67 at % Al), 63 mm in diameter (position (2a) in FIG. 2a) and for the TiN layers, pure Ti (63 mm in diameter, position (2b) in FIG. 2a) was used. The layers were deposited in 99.995% pure N₂ atmosphere at a total pressure of 4 Pa, using a bias of −40 V and an evaporation current of 60 A for both cathode materials. The variation in layer thicknesses was obtained by altering the evaporation current to the cathodes, the set-up of the deposition system (i.e., the cathode material in the four positions (2), see FIG. 2b) and the rotation speed of the fixture (see tab 1). The total coating thickness was close to 3 μm for all inserts. The deposition temperature was about 450° C.

Cross-sectional transmission electron microscopy (TEM) including scanning TEM (STEM) was used to study the microstructure of the layers. The sample preparation comprised standard mechanical grinding/polishing and ion-beam sputter etching on both upper and lower surfaces as well as cut-out of TEM samples by using focused ion beam (FIB) milling over the cutting edge of the inserts. FIG. 3 (A) is a cross sectional STEM micrograph of a multilayer coating with TiN (bright contrast) and (Ti_0.36Al_0.64)N (dark contrast). The microstructure is columnar and dense, with large single crystal grains over several interfaces (schematically shown in (B)).

The XRD patterns of the as-deposited layers were obtained using Cu K alpha radiation and a 0-20 configuration. FIG. 4 shows XRD patterns of (A) single phase (Ti_0.36Al_0.64)N layer and (B) multilayered TiN/(Ti,Al)N coating with TiN and (Ti_0.36Al_0.64)N. The indexed peaks correspond to single phase (1) TiN, (2) (Ti,Al)N and (3) cemented carbide. Similar to the results in FIG. 4, all deposited coatings summarized in tab 1 reveal single-phase cubic TiN and (Ti,Al)N structures.

The residual stresses, σ, of the TiN and (Ti_1-xAl_x)N layers of the coating were evaluated by XRD measurements (see tab 1) using the sin²ψ method. The measurements were performed using CuKα-radiation on the TiN 220- and the (Ti_1-xAl_x)N 220-reflections, respectively. Stress values for layers thinner than <4 nm could not be deduced. The goniometer setup is shown in FIG. 5. Data was obtained using the side-inclination technique (ψ-geometry) with 11, ψ-angles (positive and negative), equidistant within a sin²ψ range of 0 to 0.82)(ψ˜65°. The residual stress values were evaluated using a Possion's ratio of ν=0.25 and Young's modulus of E=450 GPa.

The total average composition of the coatings was estimated by energy dispersive spectroscopy (EDS) analysis area using a LEO Ultra 55 scanning electron microscope with a Thermo Noran EDS detector operating at 10 kV. The data were evaluated using a Noran System Six (NSS ver 2) software (see tab 1).

TABLE 1
	dTiN	d(Ti, Al)N	λ		Total coating	σTiN	σ(Ti, Al)N	Ti	Al	N
Sample	(nm)	(nm)	(nm)	N	thickness (μm)	(GPa)	(GPa)	(at %)	(at %)	(at %)

(Ti, Al)N					2.9		−3.6	18.3	31.7	50.0
TiN					3.2	−3.5		49.5		50.5
. . . TiN/Ti, Al)N/ . . .
1	1.1	4.0	5.1	569	2.9		−5.5	24.8	25.1	50.1
2	2.4	2.5	4.9	633	3.1			33.4	16.3	50.2
3	3.9	0.9	4.8	625	3.0	−7.5		43.6	6.0	50.4
4	2.0	7.9	9.9	313	3.1		−4.2	24.4	25.5	50.1
5	5.1	5.0	10.1	287	2.9	−8.7	−2.1	33.9	15.8	50.3
6	8.1	2.1	10.2	294	3.0	−6.6		43.0	6.6	50.4
7	4.1	15.9	20.0	163	3.3	−11.1	−4.3	24.5	25.4	50.1
8	10.4	10.1	20.5	161	3.3	−9.6	−3.8	34.0	15.8	50.3
9	16.2	3.8	20.0	168	3.4	−7.5	−1.0	43.5	6.1	50.4
10	10.1	39.5	49.6	69	3.4	−10.7	−4.2	24.4	25.5	50.1
11	24.8	25.1	49.9	69	3.5	−9.7	−2.3	33.7	16.1	50.2
12	40.2	10.1	50.3	70	3.5	−8.2	−1.0	43.2	6.4	50.4
13	21.5	79.0	100.5	35	3.6	−10.5	−6.4	24.7	25.2	50.1
14	49.2	50.4	99.6	36	3.6	−8.8	−4.4	33.6	16.2	50.2
15	81.2	19.2	100.4	36	3.7	−6.2	−0.9	43.5	6.1	50.4

Example 2

Example 1 was repeated but using a pure Ta cathode (63 mm in diameter, position (2b) in FIG. 2a) for growth of the TaN layers.

The total average composition of the coatings was estimated by energy dispersive spectroscopy (EDS) analysis (see example 1) and summarized in tab 2.

TABLE 2
	dTaN	d(Ti, Al)N	λ		Total coating	Ta	Ti	Al	N
Sample	(nm)	(nm)	(nm)	N	thickness (μm)	(at %)	(at %)	(at %)	(at %)

(Ti, Al)N					2.9		18.3	31.7	50.0
TaN					3.1	50.2			49.8
. . . /TaN/(Ti, Al)N/ . . .
13	0.9	4.2	5.1	608	3.1	8.9	14.8	26.4	50.0
14	2.4	2.4	4.8	625	3.0	25.1	9.0	16.0	49.9
15	4.0	1.1	5.1	588	3.0	39.4	3.9	6.9	49.8
16	2.0	8.1	10.1	287	2.9	9.9	14.4	25.7	50.0
17	5.1	4.9	10.0	310	3.1	25.6	8.8	15.7	49.9
18	8.0	2.0	10.0	290	2.9	40.2	3.6	6.4	49.8
19	4.1	16.2	20.3	148	3.0	10.1	14.4	25.5	50.0
20	10.2	10.1	20.3	153	3.1	25.2	9.0	15.9	49.9
21	15.9	4.0	19.9	141	2.8	40.1	3.6	6.4	49.8
22	9.9	40.1	50.0	62	3.1	9.9	14.4	25.7	50.0
23	25.2	24.8	50.0	64	3.2	25.3	8.9	15.9	49.9
24	40.1	10.1	50.2	60	3.0	40.1	3.6	6.4	49.8

Example 3

Example 1 was repeated but using a Ti/Nb (95 at % Ti+5 at % Nb) cathode (63 mm in diameter, position (2b) in FIG. 2a) for growth of the (Ti,Nb)N layers.

The total average composition of the coatings was estimated by energy dispersive spectroscopy (EDS) analysis (see example 1) and summarized in tab 3.

TABLE 3
	d(Ti, Nb)N	d(Ti, Al)N	λ		Total coating	Nb	Ti	Al	N
Sample	(nm)	(nm)	(nm)	N	thickness (μm)	(at %)	(at %)	(at %)	(at %)

(Ti, Al)N					2.9		18.3	31.7	50.0
(Ti, Nb)N					3.0	2.3	47.7		50.0
. . . /(Ti, Nb)N/(Ti, Al)N/ . . .
25	1.0	4.1	5.1	608	3.1	0.5	23.8	25.7	50.0
26	2.5	2.6	5.1	569	2.9	1.1	32.6	16.3	50.0
27	4.1	1.1	5.2	558	2.9	1.8	41.4	6.8	50.0
28	2.2	8.2	10.4	288	3.0	0.5	24.3	25.2	50.0
29	5.1	5.0	10.1	287	2.9	1.2	33.0	15.8	50.0
30	7.9	1.9	9.8	306	3.0	1.9	41.9	6.2	50.0
31	4.1	16.0	20.1	134	2.7	0.5	24.1	25.5	50.0
32	10.1	9.8	19.9	156	3.1	1.2	33.1	15.8	50.0
33	16.2	3.9	20.1	144	2.9	1.9	41.9	6.2	50.0
34	9.9	40.1	50.0	62	3.1	0.5	23.9	25.7	50.0
35	25.0	24.9	49.9	60	3.0	1.2	32.9	16.0	50.0
36	39.6	10.1	49.7	56	2.8	1.8	41.7	6.5	50.0

Example 4

Example 1 was repeated but using a pure Nb cathode (63 mm in diameter, position (2b) in FIG. 2a) for growth of the NbN layers.

The total average composition of the coatings was estimated by energy dispersive spectroscopy (EDS) analysis (see example 1) and summarized in tab 4.

TABLE 4
	dNbN	d(Ti, Al)N	λ		Total coating	Nb	Ti	Al	N
Sample	(nm)	(nm)	(nm)	N	thickness (μm)	(at %)	(at %)	(at %)	(at %)

(Ti, Al)N					2.9		18.3	31.7	50.0
NbN					3.2	49.9			50.1
. . . /NbN/(Ti, Al)N/ . . .
37	1.0	4.0	5.0	540	2.7	10.0	14.4	25.6	50.0
38	2.4	2.7	5.1	549	2.8	23.5	9.5	16.9	50.0
39	4.1	1.2	5.3	547	2.9	38.6	4.1	7.2	50.1
40	2.1	8.3	10.4	298	3.1	10.1	14.4	25.5	50.0
41	5.1	4.7	9.8	286	2.8	26.0	8.6	15.3	50.1
42	8.0	2.1	10.1	307	3.1	39.5	3.7	6.7	50.1
43	4.0	15.8	19.8	157	3.1	10.1	14.4	25.5	50.0
44	9.9	8.9	18.8	149	2.8	26.3	8.5	15.1	50.1
45	15.8	4.0	19.8	141	2.8	39.8	3.6	6.5	50.1
46	10.0	39.4	49.4	57	2.8	10.1	14.4	25.5	50.0
47	24.5	25.0	49.5	63	3.1	24.7	9.1	16.2	50.0
48	41.0	9.8	50.8	57	2.9	40.3	3.5	6.2	50.1

Example 5

Example 1 was repeated but using a pure Zr cathode (63 mm in diameter, position (2b) in FIG. 2a) for growth of the ZrN layers.

The total average composition of the coatings was estimated by energy dispersive spectroscopy (EDS) analysis (see example 1) and summarized in tab 5.

TABLE 5
	dZrN	d(Ti, Al)N	λ		Total coating	Zr	Ti	Al	N
Sample	(nm)	(nm)	(nm)	N	thickness (μm)	(at %)	(at %)	(at %)	(at %)

(Ti, Al)N					2.9		18.3	31.7	50.0
ZrN					3.0	50.7			49.3
. . . /ZrN/(Ti, Al)N/ . . .
49	1.0	3.8	4.8	604	2.9	10.6	14.3	25.3	49.9
50	2.6	2.2	4.8	560	2.7	27.5	8.3	14.7	49.6
51	3.9	1.1	5.0	560	2.8	39.5	4.0	7.0	49.5
52	2.1	8.3	10.4	288	3.0	10.2	14.4	25.5	49.9
53	5.0	5.1	10.1	287	2.9	25.1	9.1	16.2	49.7
54	7.8	2.4	10.2	284	2.9	38.8	4.2	7.5	49.5
55	3.9	16.0	19.9	156	3.1	9.9	14.5	25.7	49.9
56	10.0	9.7	19.7	152	3.0	25.7	8.9	15.8	49.6
57	16.1	3.5	19.6	153	3.0	41.6	3.2	5.7	49.4
58	9.8	39.4	49.2	59	2.9	10.1	14.4	25.6	49.9
59	25.5	25.0	50.5	59	3.0	25.6	8.9	15.8	49.6
60	40.0	10.0	50.0	58	2.9	40.6	3.6	6.4	49.4

Example 6

Example 2 was repeated but using a pure V cathode (63 mm in diameter, position (2b) in FIG. 2a) for growth of the VN layers.

The total average composition of the coatings was estimated by energy dispersive spectroscopy (EDS) analysis (see example 1) and summarized in tab 6.

TABLE 6
	dVN	d(Ti, Al)N	λ		Total coating	V	Ti	Al	N
Sample	(nm)	(nm)	(nm)	N	thickness (μm)	(at %)	(at %)	(at %)	(at %)

(Ti, Al)N					2.9		18.3	31.7	50.0
VN					3.3	51.3			48.7
. . . VN/(Ti, Al)N/ . . .
61	0.8	4.2	5.0	600	3.0	8.2	15.1	26.9	49.8
62	2.3	2.8	5.1	608	3.1	23.1	9.9	17.6	49.4
63	3.9	1.2	5.1	608	3.1	39.2	4.2	7.5	49.0
64	2.0	8.3	10.3	262	2.7	10.0	14.5	25.8	49.7
65	5.0	5.4	10.4	279	2.9	24.7	9.3	16.6	49.4
66	7.8	2.8	10.6	292	3.1	37.7	4.8	8.5	49.0
67	3.8	16.0	19.8	162	3.2	9.8	14.5	25.9	49.8
68	10.0	9.7	19.7	157	3.1	26.0	8.9	15.8	49.3
69	16.4	3.5	19.9	146	2.9	42.3	3.2	5.6	48.9
70	10.4	41.0	51.4	54	2.8	10.4	14.4	25.5	49.7
71	24.8	26.5	51.3	57	2.9	24.8	9.3	16.5	49.4
72	39.0	10.5	49.5	57	2.8	40.4	3.8	6.8	49.0

Example 7

Example 2 was repeated but using a Al/Ti (95 at % Al+5 at % Ti) cathode (63 mm in diameter, position (2b) in FIG. 2a) for growth of the (Al,Ti)N layers.

The total average composition of the coatings was estimated by energy dispersive spectroscopy (EDS) analysis (see example 1) and summarized in tab 7.

TABLE 7
	d(Ti, Al)N-L1	d(Ti, Al)N-L2	λ		Total coating	Ti	Al	N
Sample	(nm)	(nm)	(nm)	N	thickness (μm)	(at %)	(at %)	(at %)

(Ti, A1)N-L1					2.9	18.3	31.7	50.0
(Ti, Al)N-L2					3.2	46.4	3.6	49.8
. . . /(Ti, Al)N-L2/(Ti, Al)N-L1/ . . .
73	1.0	3.9	4.9	633	3.1	23.8	26.2	50.0
74	2.5	2.6	5.1	569	2.9	31.9	18.2	49.9
75	4.0	0.8	4.8	604	2.9	41.7	8.5	49.8
76	2.1	8.1	10.2	294	3.0	23.8	26.2	50.0
77	5.1	4.9	10.0	290	2.9	32.5	17.6	49.9
78	8.1	1.8	9.9	303	3.0	41.2	8.9	49.8
79	3.9	15.8	19.7	137	2.7	23.6	26.4	50.0
80	9.9	11.0	20.9	148	3.1	31.5	18.6	49.9
81	15.9	4.2	20.1	144	2.9	40.5	9.7	49.8
82	10.1	39.8	49.9	62	3.1	23.7	26.3	50.0
83	25.1	24.9	50.0	60	3.0	32.3	17.8	49.9
84	40.1	9.4	49.5	57	2.8	41.0	9.2	49.8

Example 8

Inserts from example 1 were tested according to:

Geometry: CNMG120408-MF1

Application: Continuous turning
Work piece material: AISI 316L
Cutting speed: 230 m/min
Feed: 0.15 mm/rev

Depth of cut: 1 mm

Tool life criteria, flank wear (vb)>0.3 mm
Result of test

TABLE 8
					Total
					coating	Tool
	dTiN	d(Ti, Al)N	λ		thickness	life
Sample	(nm)	(nm)	(nm)	N	(μm)	(min)

(Ti, Al)N					2.9	18.2
TiN					3.2	9.3
. . . /TiN/(Ti, Al)N/ . . .
1	1.1	4.0	5.1	569	2.9	20.8
2	2.4	2.5	4.9	633	3.1	18.7
3	3.9	0.9	4.8	625	3.0	12.8
4	2.0	7.9	9.9	313	3.1	22.1
5	5.1	5.0	10.1	287	2.9	18
6	8.1	2.1	10.2	294	3.0	12.9
7	4.1	15.9	20.0	163	3.3	19.5
8	10.4	10.1	20.5	161	3.3	16.5
9	16.2	3.8	20.0	168	3.4	11.8
10	10.1	39.5	49.6	69	3.4	18.5
11	24.8	25.1	49.9	69	3.5	16.3
12	40.2	10.1	50.3	70	3.5	11.1
13	21.5	79.0	100.5	35	3.6	18.1
14	49.2	50.4	99.6	36	3.6	14.4
15	81.2	19.2	100.4	36	3.7	11

Example 9

Inserts from example 1 were tested according to:

Geometry: CNMG120412-MR3

Application: Continuous turning
Work piece material: Inconel 718,
Cutting speed: 90 m/min
Feed: 0.2 mm/rev

Depth of cut: 0.5 mm

Tool life criteria, flank wear (vb)>0.2 mm
Result of test

TABLE 9
					Total
					coating	Tool
	dTiN	d(Ti, Al)N	λ		thickness	life
Sample	(nm)	(nm)	(nm)	N	(μm)	(min)

(Ti, Al)N					2.9	10.9
TiN					3.2	5.2
. . . /TiN/(Ti, Al)N/ . . .
1	1.1	4.0	5.1	569	2.9	12.5
2	2.4	2.5	4.9	633	3.1	9.6
3	3.9	0.9	4.8	625	3.0	7.1
4	2.0	7.9	9.9	313	3.1	12.2
5	5.1	5.0	10.1	287	2.9	10.1
6	8.1	2.1	10.2	294	3.0	7.5
7	4.1	15.9	20.0	163	3.3	11.2
8	10.4	10.1	20.5	161	3.3	8.9
9	16.2	3.8	20.0	168	3.4	7.9
10	10.1	39.5	49.6	69	3.4	10.8
11	24.8	25.1	49.9	69	3.5	7.5
12	40.2	10.1	50.3	70	3.5	7.1
13	21.5	79.0	100.5	35	3.6	8.2
14	49.2	50.4	99.6	36	3.6	6.2
15	81.2	19.2	100.4	36	3.7	6.2

Example 10

Inserts from example 5 were tested according to:

Geometry: CNMG120408-MF1

Application: Continuous turning
Work piece material: AISI 316L
Cutting speed: 250 m/min
Feed: 0.15 mm/rev

Depth of cut: 1 mm

Tool life criteria, flank wear (vb)>0.3 mm
Result of test

TABLE 10
					Total
					coating	Tool
	dZrN	d(Ti, Al)N	λ		thickness	life
Sample	(nm)	(nm)	(nm)	N	(μm)	(min)

(Ti, Al)N					2.9	18.2
ZrN					3.0	9.7
. . . /ZrN/(Ti, Al)N/ . . .
49	1.0	3.8	4.8	604	2.9	20.4
50	2.6	2.2	4.8	560	2.7	17.5
51	3.9	1.1	5.0	560	2.8	11.9
52	2.1	8.3	10.4	288	3.0	21.6
53	5.0	5.1	10.1	287	2.9	16.9
54	7.8	2.4	10.2	284	2.9	11.8
55	3.9	16.0	19.9	156	3.1	18.9
56	10.0	9.7	19.7	152	3.0	15.6
57	16.1	3.5	19.6	153	3.0	10.9
58	9.8	39.4	49.2	59	2.9	18.3
59	25.5	25.0	50.5	59	3.0	15.4
60	40.0	10.0	50.0	58	2.9	10.4

Example 11

A used insert from example 8 was studied in more detail by TEM including electron diffraction, STEM and EDS. FIG. 6 (A) shows a STEM micrographs of the coating of sample 4 (Tab 1). The image shows TiN rich regions (brighter contrast) and AlN rich regions (darker contrast). This is further verified by the EDS mapping in (C) and (D) showing the EDS maps of Ti (bright areas show Ti rich regions) and Al (bright areas show Al rich regions), respectively. Further, the typical size of the Ti and Al rich regions is on the order of 5 nm. Selected area electron diffraction patterns (B) show coherency and cubic structure over the layered structure.